Manufacture of filaments of varying denier



March 20, 1962 I A. J. CARMAN ETAL MANUFACTURE OF FILAMENTS OF VARYING DENIER 2 Sheets-Sheet 1 Filed May 15, 1958 March 20, 1962 A. J. CARMAN ETAL MANUFACTURE OF FILAMENTS OF VARYING DENIER Filed May 15, 1958 Tin- 2 Sheets-Sheet 2 its Filed May 15, 1958, Ser. No. 735,631 9 Claims. c1. 18-8) The invention relates to the manufacture of filamentary material, and is more particularly directed to improvements in apparatus for making filamentary material of uneven or varying denier.

In one method of making filamentary material of varying denier, the thickness of the material is varied by intermittently or alternately increasing and decreasing the draw-down, which may be defined as the ratio between the linear speed at which the material is taken up and the linear speed at which it leaves its source, e.g. the linear speed of extrusion of a dope of filament-forming material. Generally, the increase in draw-down has been accomplished by deflecting the filaments as formed out of their normal paths to increase the tension upon the filaments and produce a thin portion, after which draw-down is decreased by allowing the filaments to return to their normal running paths to produce a second portion of normal thickness, i.e. of greater diameter than the first or thin portion. The relatively thick portions of the filaments or yarns are known as slubs, and it is a well-recognized objective to produce filaments having well-defined or pronounced slubs. This is accomplished by abruptly releasing the deflected filament.

Numerous devices have been proposed and used to vary draw-down by intermittently deflecting the filamentary material out of its normal running path, and then releasing the tension upon the filamentary material. Such devices have taken various forms, including filament-engaging rolls of non-circular cross-section, variously actuated oscillating arms, and specially shaped drums and earns. The intrinsic construction or design of these prior art devices restricts the measure of control and latitude desired in processing the filamentary materials, and have limited (a) the rate of producing the filamentary material, or (b) the frequency or degree of randomness of the slubs, or (c) the variations in length of the slubs, or (d) the variations in length of the thin portions immediately preceding the slubs, which thin portions actually control the yarn tenacity and elongation, being the weakest section in the yarn, or (e) the ratio of the denier of the slub to the denier of the yarn when not being slubbed, or a combination of two or more of these factors.

A primary object of the invention is to provide an improved apparatus for varying draw-clown, which enables the processing of filamentary materials at a rate as much as 200% higher than is possible using other apparatus such as a single shaft driving a plurality of lifter arms, each arm of which is oscillated to displace an end of yarn.

Another important object of the invention is to provide an apparatus for varying draw-down, which affords close control and wide latitude in the selection of speed of production, of the slub length, of the slub denier, of the slub spacing, and of the length of the thin portions.

Other objects of this invention Will be apparent from the following detailed description and the claims.

In accordance with one aspect of the present invention there is provided an apparatus including means for supplying filamentary material and draw-otf means providing a normal path of travel for the filamentary material between the supply means and the draw-01f means. Preferably, the filamentary material is drawn off at a constant speed, although, if desired, the draw-off means may be driven at varying speed. Intermediate the supply means and the draw-01f means there is provided a support having a plurality of spaced, filament-engaging projections. The support or carrier is of substantial or extended length, and for convenience is in the form of a flexible endless belt or chain, to which the projections are individually secured. The flexible support is suitably mounted and driven to travel adjacent to and transversely of the normal path of the filament material so that the projections, which are spaced longitudinally along the flexible support, intermittently engage and deflect the filamentary material out of its normal path. The projections may be of any suitable forrn, such as pins or wire connected to the flexible support, means being provided to displace either the pin or the filamentary material so as to release the filamentary material after it has been deflected a selected or predetermined distance from its normal path. If desired, this can be effected automatically as a result of the angle of engagement between the filamentary material and transversely traveling projection, the filamentary material moving off the projection toward its normal path. Alternately the pins may be spring loaded so as to release the filamentary material at a predetermined tension, the pins may be rotated backward or forward to release the filamentary material, fixed or movable guides may lift the filamentary material off the pins, etc.

When a projection engages the running filamentary material and deflects it from its normal running path, the filamentary material is reduced in thickness, and when the filamentary material is released into the space rear- Wardly of the projection, and before engagement by the next or succeeding projection, the unrestrained or less restrained running filamentary material assumes greater thickness to provide a slub. Due to the flexible character of the support for the filament-engaging projections, which permits the support to be of extended or substantial length, considerable latitude is afforded in the disposition of the projections relative to each other. As a result, the slubs can be produced at high speeds and with considerable randomness and variations in slub length. Slubs ranging in length from A1 inch to 8 inches or more and spaced any desired distance apart are within the range of the apparatus of the invention. Also, by varying the lengths of the projections or by arranging selected projections at different angles relative to the support the deflected filamentary material is released at different distances from its normal running path, thereby to provide variations in the lengths of the thin portions; the extent of deflection also controls the time of return which in turn controls the length of the transition Zone along the fiber from a section of greatest diameter to a section of minimum diameter. Moreover, the latitude allowed in the positioning of the projections, and their spacing from one another, permits the disposition of a projection for engagement with the filamentary material before the filamentary material returns to its normal running path.

When control of denier variation is achieved by a cam, the slub pattern will repeat at a distance approximately equal to the periphery of the cam. Even if the rotational speed of the cam is varied the successive series of the slubs will be similar, producing a pattern or Window effect. The use of an elongated support for the projections in accordance with the present invention, however, increases tremendously the distance between repeats so that a more random yarn results. In addition, a single elongated support can operate simultaneously on a multiplicity of filamentary materials, as for instance on the filamentary materials issuing from a metier including or more ends of yarn so as to decrease the equipment cost per end of yarn. Moreover, whereas it is necessary to provide a new cam for each metier when it is desired to change the pattern of slubs produced by cam control, in accordance with the present invention it is only necessary to move the projections to new location along the same support or even more simply, to vary the belt speed or the position of a yarn guide just before the take-up roll for each end of yarn.

The novel apparatus can be used in varying the denier of any filamentary material which is formed by spinning or extrusion, either dry-, wetor melt spinning, followed by application of tension to draw it to proper denier. Representative filament-forming materials include organic derivatives of cellulose such as ethers and esters, e.g. cellulose acetate, regenerated cellulose, etc., polyamides such as nylon, e.g. polyhexamethylene adipamide, and polyesters, such as polyethylene terephthalate. Moreover, the invention may also be employed for imparting a varying denier during the stretching of previously spun filaments. In such a case, instead of a spinning metier for the production of artificial filaments, there are provided means for supplying previously spun filamentary materials and means for bringing the filaments to a plastic and stretchable condition in a zone for heating the filaments, or for applying to them a suitable softening agent, for example, solvents, solvent vapors, hot water or moist steam. Also, the invention may be used for the colddrawing of filamentary material, such as nylon, to produce a cold-drawn material of varying denier. The invention can also operate on a roving of staple fibers between the front and rear draft rolls of a spinning frame so as to vary the draft, thereby to produce thick and thin spun yarn, the drafted roving being twisted beyond the front rolls as it is taken up on a bobbin.

In the drawings, wherein several embodiments of the invention are illustrated,

FIG. 1 is a generally diagrammatic perspective view of the apparatus of the invention for imparting varying denier to filamentary material as dry spun and before being taken up,

FIG. 2 is a partial side view showing the manner in which the filamentary material is deflected from its normal running path in accordance with the present invention,

FIG. 3 is a top plan view of the arrangement shown in FIG. 2, this view also showing a plurality of individual running filamentary materials being simultaneously processed by a single flexible support having spaced, filamentengaging projections,

FIG. 4 illustrates another form of the invention, and

FIG. 5 shows still another form of the invention.

As shown in FIG. 1, the filament source may be a spinning cabinet 11 wherein a spinning solution or dope under pressure is extruded at a uniform rate through the fine orifices of a spinnerette 12 downward into an evaporative atmosphere to form a plurality of continuous filaments 13. The filaments may be brought together to form a bundle or yarn 14, which is drawn from the cabinet by the action of draw-off means or draw roller 16. Preferably, the draw roller is positively driven at constant speed. The yarn 14 is then wound in the conventional manner on a bobbin 17 by means of the usual ring-spinning arrangement 18. In traveling from the cabinet 11 to the draw roller 16, the yarn passes through a pigtail guide 19 and over a furnishing roller 20, which applies a suitable lubricant, contained in a trough 21, to the yarn.

A flexible support 22, in the form of an endless belt having a plurality of spaced filament engaging projections or pins 23 bolted thereto, is positioned between the filament source, or spinning cabinet 11, and the draw-01f means, or roller 16. The belt is mounted for travel about a pair of spaced rolls 24, 25, one or both of which are driven by any suitable means (not shown). In the form of the invention illustrated in FIGS. 1 and 2, the belt is located so that the upper reach thereof and its projections travel rectilinearly and transversely to the normal path of the running yarn 14, with the pins 23 successively engaging and then releasing the yarn. The normal path of the yarn 14 is defined by restraining means such as pigtail guides 26 and 27 located on each side of the traveling belt, The positioning of these guides can be varied to produce corresponding variations in the length and diameter of the slubs and the thin portions between slubs.

As more particularly shown in FIG. 2, the filamentengaging pins 23 are preferably rearwardly inclined with respect to the direction of travel of the flexible belt 22. As shown in FIG. 3, pin 23 initially engages the yarn 4, running in its normal path. As the pin 23 advances to the right, it gradually deflects the yarn a predetermined distance to the position indicated by the broken line, where, due to the angle of engagement between the rearwardly inclined pin and the filament, the filament is auto matically and abruptly released into the space rearward of the pin 23 to resume its normal running path and then to be engaged by the next succeeding pin 23a. With the guides 26, 27 located on a level between the upper extremities of the pins and the plane of the upper reach of the traveling belt, the distance the filament is deflected from its normal path may be varied by changing the inclination or length of a pin within the limits of the clasticity of th filament.

As shown in FIGURE 3, another yarn 14a may run parallel to yarn 14 and will also be acted upon by pins 23, 23a as the belt 22 advances. As many yarns can be acted upon simultaneously by a single belt as there are spinning cabinets in a metier.

Instead of the belt or chain running in a horizontal plane where the projections engage the yarn 14, as shown in FIG. 4 there may be provided rolls 28, 29 at different elevations so that a belt 30 trained thereabout will travel an essentially inclined path. The belt 30 may be provided with pins 31 which project therefrom at substantially right angles to provide the desired angle of engagement to release the filament after being deflected a predetermined distancefrom its normal path.

It is also within the scope of the invention to provide an arrangement such as shown in FIG. 5, wherein a flexible belt or chain 32 is mounted for travel in a substantially vertical plane, the belt 32 being provided with projections 33 engaging the yarn 14 to deflect it transversely of its normal path and release it as a projection travels about a curved path or arc. The yarn 14 is engaged at its normal running path, and when the projection 33 reaches the point indicated in broken lines it moves out from under the yarn 14 to release same.

Other modifications and changes will be apparent from the more detailed forms of the invention as hereinbefore described. Essentially, the advantages of the invention in producing filament, yarns, or the like, of varying denier at an increased rate, while realizing a high degree of slub frequency, coupled with wide variations in slub length, and variations in length of the thin portions, are obtained by supporting the filament-deflecting projections upon a flexible carrier permitting the use of an extended length thereof, and thereby providing a large measure of selectivity in the positioning and spacing of the projections, as well as the ability to orient the individual projections for varied or different amounts of deflection of the filament. In addition, since the slubbing is achieved without oscillation of any elements, vibration is not encountered and it becomes possible to operate at high speeds.

It is to be understood that the foregoing detailed description is given merely by way of illustration and that many variations may be made therein without departing from the spirit of our invention.

Having described our invention what we desire to secure by Letters Patent is:

1. In apparatus for making filamentary material of varying denier comprising means for supplying filamentary material and draw-off means for the filamentary material between which the filamentary material travels a normal path, the improvement for intermittently increasing and decreasing the length of the path of the filamentary material between the supply and the draw-on. means comprising a support of substantial length having a plurality of filament-engaging projections, said support being mounted to travel adjacent and transverse to the normal path of the filamentary material, the projections being spaced apart in the direction of movement of the support successively to efiect the filamentary material transversely of its path, engagement between each of the projections and the filamentary material being terminated when each projection has moved a predetermined distance from the point Where it first contacts the filamentary material.

2. In apparatus for making filamentary material of varying denier comprising means for supplying filamentary material and draw-off means for the filamentary material between which the filamentary material travels a normal path, the improvement for intermittently increasing and decreasing the length of the path of the filamentary material between the supply and the draw-off means comprising a support of substantial length having a plurality of filament-engaging projections, said support being mounted to travel adjacent and transverse to the normal path of the filamentary material, the projections being spaced apart in the direction of movement of the support successively to deflect the filamentary material transversely of its path, the filament-engaging surface of each of the projections being inclined rearwardly with respect to the direction of movement of the support, whereby the filamentary material is released when the projection has moved a predetermined distance from the point where it first contacts the filamentary material.

3. In apparatus for making filamentary material of varying denier comprising means for supplying filamentary material and draw-oft means for the filamentary material between which the filamentary material travels a normal path, the improvement for intermittently increasing and decreasing the length of the path of the filamentary material between the supply and the draw-oil means comprising an endless flexible support of substantial length having a plurality of filament-engaging projections, said support being mounted to travel rectilinearly adjacent and transverse to the normal path of the filamentary material, the projections being spaced apart in the direction of movement of the support successively to deflect the filamentary material transversely of its path, the angle of engagement between each of the projections and the filamentary material causing the filamentary material to be released when a projection has moved a predetermined distance from the point where it first contacts the filamentary material.

4. In apparatus for making filamentary material of varying denier comprising means for supplying filamentary material and draW-ofi means for the filamentary material between which the filamentary material travels a normal path, the improvement for intermittently increasing and decreasing the length of the path of the filamentary material between the supply and the draw-cit means comprising an endless flexible support of substantial length having a plurality of filament-engaging projections, said support being mounted to travel rectilinearly adjacent and transverse to the normal path of the filamentary material, the projections being spaced apart in the direction of movement of the support successively to deflect the filament transversely of its path, the filamentengaging surface of each of the projections being inclined rearWardly with respect to the direction of movement of the support, whereby the filamentary material is released when the projection has moved a predetermined distance from the point where it first contacts the filamentary material.

5. An apparatus for making filamentary material of varying denier comprising a plurality of means for supplying filamentary material and a plurality of draw-ofi means for the respective filamentary materials between which the filamentary materials respectively travel normal paths, and means for varying draw-down of the filamentary materials by intermittently increasing and decreasing the lengths of the paths of the filamentary materials between their respective supply and draw-off means, said carrying draw-down means comprising an endless flexible support of substantial length having a plurality of filament-engag ing projections, said support being mounted to travel adjacent and transverse to the normal paths of the filamentary materials, the projections being spaced apart in the direction of movement of the support successively to deflect each of the filamentary materials transversely of is respective path, the angle of engagement between each of the projections and each filamentary material causing the filamentary material to be released when a projection has moved a predetermined distance from the point where it first contacts the filamentary material.

6. An apparatus according to claim 5, wherein said plurality of means for supplying filamentary material comprises a plurality of spinning cabinets.

7. In apparatus for making filamentary material of varying denier comprising means for supplying filamentaiy material and draw-ofl means for the filamentary material between which the filamentary material travels a normal path, the improvement for intermittently increasing and decreasing the length of the path of the filamentary material between the supply and the draw-off means comprising an endless flexible support of substantial length having a plurality of filament-engaging projections, said support being mounted to travel rectilinearly adjacent and transverse to the normal path of the filamentary material, the projections being spaced apart in the direction of movement of the support successively to deflect the filament transversely of its path, the filamentengaging surface of each of the projections being inclined rearwardly with respect to the direction of movement of the support, whereby the filamentary material is released when the projection has moved a predetermined distance from the point Where it first contacts the filamentary material.

8. An apparatus for making filamentary materials of varying denier comprising a plurality of means for supplying filamentary material, a plurality of means or separately drawing off said filamentary materials, an elongated support extending transversely of the paths which said filamentary materials take in moving from said supplying means to said drawing off means, said support being provided with a plurality of projections, and means for moving said support longitudinally, so that each projection in turn contacts successive filamentary materials, the projections efiecting intermittent deflection of the filamentary materials thereby intermittently increasing the paths of said materials and decreasing their denier.

9. An apparatus according to claim 8, wherein said means for supplying filamentary material comprises a spinning cabinet.

References Cited in the file of this patent UNITED STATES PATENTS 1,898,085 Dreyfus et al Feb. 21, 1933 2,038,722 Dreyfus et al Apr. 28, 1936 2,825,199 Hicks Mar. 4-, 1958 2,920,345 Dyer Jan. 12, 1960 

